EP0496181B1 - Verfahren zur Herstellung von metallischen Werkstücken mit einer Schweissvorrichtung und Vorrichtung zur Ausführung desselben - Google Patents

Verfahren zur Herstellung von metallischen Werkstücken mit einer Schweissvorrichtung und Vorrichtung zur Ausführung desselben Download PDF

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Publication number
EP0496181B1
EP0496181B1 EP91810999A EP91810999A EP0496181B1 EP 0496181 B1 EP0496181 B1 EP 0496181B1 EP 91810999 A EP91810999 A EP 91810999A EP 91810999 A EP91810999 A EP 91810999A EP 0496181 B1 EP0496181 B1 EP 0496181B1
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EP
European Patent Office
Prior art keywords
welding
workpiece
equipment
weld material
layers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP91810999A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP0496181A1 (de
Inventor
Fritz Schneebeli
Bruno Tanner
Olivier Braun
Roger Dekumbis
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Andritz Hydro AG
Original Assignee
Andritz Hydro AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Andritz Hydro AG filed Critical Andritz Hydro AG
Publication of EP0496181A1 publication Critical patent/EP0496181A1/de
Application granted granted Critical
Publication of EP0496181B1 publication Critical patent/EP0496181B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding
    • B23K9/044—Built-up welding on three-dimensional surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/32—Bonding taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/001—Interlayers, transition pieces for metallurgical bonding of workpieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding
    • B23K9/044—Built-up welding on three-dimensional surfaces
    • B23K9/046—Built-up welding on three-dimensional surfaces on surfaces of revolution
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03B—MACHINES OR ENGINES FOR LIQUIDS
    • F03B1/00—Engines of impulse type, i.e. turbines with jets of high-velocity liquid impinging on blades or like rotors, e.g. Pelton wheels; Parts or details peculiar thereto
    • F03B1/02—Buckets; Bucket-carrying rotors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/20—Hydro energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the invention relates to a method for producing metallic Workpieces with a welding device, in particular of workpieces made from highly tempered materials, an apparatus for performing the method and a Pelton wheel thus obtainable.
  • a metallic, prefabricated support body to which the first layer of welding material is applied, is usually used to support the liquid, molten welding material.
  • a cylinder is used as a support body for a cylindrical workpiece. The support body thus determines the general shape of the cross section of a workpiece to be produced. It has the disadvantage that a correspondingly geometrically prefabricated support body is necessary for each workpiece, which, since the support body has a metallic connection with the applied welding material layers, may have to be removed again.
  • EP 0 170 780 describes a process for the production of Rotational bodies made of weld metal are known as spatial curved components are designed. There is a component clamped on a turntable with clamping devices. That on a turntable spanned component rotates around it Rotation axis, the application area of the component is kept continuously in a horizontal welding position, so that weld metal is applied in layers and a Rotating body-shaped component is created.
  • a crucial one The disadvantage of this method is that exclusively rotationally shaped, spatially curved Components can be produced.
  • the object of the present invention is therefore to Welding material webs of any kind, also three-dimensional Curve shapes and largely constant quality to be deposited in such a way that workpieces with practically any Shapes emerge, with no support body or more special Manipulator to support the melted Welding material is necessary.
  • the object is achieved according to the invention with a method comprising the features of independent claim 1, solved.
  • the dependent claims relate to advantageous forms of the method.
  • An inventive one Device is characterized by the features of the independent Claim 8 marked.
  • the dependent claims relate to advantageous embodiments of the Contraption.
  • An inventive product of the process is a Pelton wheel, comprising the features of independent claim 12.
  • the depend Claim 13 relates to an advantageous embodiment of the product.
  • the inventive method for shaping Build-up welding of workpieces hereinafter also called Free-form method or free-form welding is called possible thanks to a combination of contract welding technology, Computer technology and robotics.
  • the applied Welding process as well as the metallic used Materials are known.
  • Powerful CAD computer programs allow the design of complex, two or three dimensional models of Workpieces made directly using the free-form method can be produced as metallic workpieces.
  • the workpiece is usually divided into a base body and a Large number of welded material strips disassembled on the Base body are applied beginning and thus the shape of the workpiece.
  • the base body serves as a carrier a first layer of welding material.
  • the entire Workpiece is deposited on the base body by Welding material webs built up, the base body a prefabricated sub-component of the final workpiece, e.g. can be a hub or a component, e.g. a The plate, which is removed from the surface in a subsequent operation Workpiece is separated.
  • the base body and / or the Are welding torches that deposit welding material preferably with the help of robots, two or three-dimensionally movable in space.
  • the default values of Computer system for the control and welding data become one System control supplied to the robot (s) and Welding device during the manufacture of the metallic Controls, monitors and continuously controls the workpiece Corrects deviations.
  • Free-form welding is done without the liquid Supporting body supporting welding material carried out, such that a newly applied, liquid welding material web is liable on the underlying track and under none Under certain circumstances.
  • a preferably vertical one Welding material application on a little bit compared to the The horizontal inclined track element reduces the Risk of drainage of the welding material.
  • the system control therefore continuously regulates the geometric position of the Underlay of a welding material web to be applied and / or the position of the welding torch and the position to be applied Welding material application rate and / or the Welding track speed.
  • Sheet-like layers can e.g. with a large welding material application rate and e.g. meandering welding tracks are created, e.g. Edges of a workpiece, due to the risk of runoff, created with a reduced welding material application rate will.
  • the welding material application rate is also such regulated that irregularities existing Welding material webs in terms of width and / or height detected and with the newly applied Welding material web can be compensated.
  • Arc welding processes can cause irregularities relatively easy by monitoring welding parameters how welding current and welding voltage are determined.
  • For laser welding processes are more demanding mechanical ones or optical sensors necessary to detect irregularities to detect existing welding material tracks. Therefore can also be very different from the laser welding process Horizontal inclined welding tracks without risk of runoff be applied when the weld pool is small, and thus is held by the surface tension.
  • workpieces of any size can be manufactured using the free-form method.
  • workpieces produced by build-up welding have better mechanical properties, since the cooling rate of the metal is easier to control and thus more homogeneous microstructures can be achieved. For this reason, workpieces with large wall thickness differences, for example, can be manufactured more easily than with the casting process.
  • Free-form welding can replace known methods for producing metallic workpieces such as casting or forging, or can be used in combination with known methods.
  • a workpiece can be constructed from one or more weldable metals and / or metal alloys, in which, for example, a high-quality, metallic cover layer is applied after the production of a metallic filler.
  • Workpieces with customer-specific mechanical, physical and corrosion-related properties can be produced.
  • the method according to the invention for free-form welding is suitable, for example, for the rapid production of individual, high-tempered workpieces as are required in prototype construction, for the repair of workpieces such as Pelton blades as well as for the production of complex workpieces such as entire Pelton wheels.
  • a device for shaping build-up welding becomes welding material in sheet-like layers on which Starting surface of a base body, applied, and thus a workpiece is manufactured, the base body being a Can be part of the workpiece.
  • the history sheet-like layers as well as the approximate Welding material application rate are from a computer system, starting from a software, two or three-dimensional data model of the workpiece, calculated and the system control, which is the welding torch with the help of the robot as well as that on one Positioning device, a turntable with a Clamping device, workpiece fixed to each other positioned and the applied Regulates welding material application rate on the welding machine in such a way that the liquid welding material on the underlying one Layer adheres without draining and irregularities web-like layers can be compensated.
  • metallic workpieces with a wide variety of body shapes, theoretically of any size and with any wall thickness, also consisting of different metallic Materials, without auxiliary cores or other the liquid Devices supporting welding material through shaping Surfacing.
  • Fig. 1 shows the build-up welding device for the production of metallic workpieces.
  • the workpiece 1 is applied to an electrically conductive base body 2 by means of shaping welding.
  • the base body 2 is either a component of the final workpiece 1, for example a holder made of metallic material, or an auxiliary body which is separated from the workpiece in a subsequent machining step.
  • a clamping device 3 which can also be cooled and / or heated, fixes the base body 2.
  • the workpiece can also be cooled or heated by other devices, not shown, preferably by an air nozzle for cooling or a gas burner for heating.
  • a three-dimensionally movable clamping device 3, which is controlled by a system controller 10, may be required for the production of complex workpieces 1.
  • a rotary table that is rotatable about two axes is used as the positioning device 4.
  • the welding torch 7 is supplied with energy, welding wire 6 and protective gas 9 by the welding device 8.
  • the system controller 10 positions the welding torch 7 with the aid of the robot 5 and the workpiece 1 with the aid of the turntable in such a way that the tangent of the web-shaped layer element to be applied is preferably approximately horizontal and with the welding torch perpendicular or in an angular range of approximately ⁇ 10 ° to the vertical is easily butted or pulled.
  • the system controller 10 regulates the applied welding material application rate according to a concept described in FIG. 4. Starting from a three-dimensional model of the workpiece 1, the computer system 11 calculates the path of the welding material layers, if necessary the dimension of the base body 2, and an approximate welding material application rate and / or welding path speed, and transmits the values to the system controller 10.
  • the base body 22 is preferably, continuously, Welding material applied in web-shaped layers, so that the body of the workpiece 21 is formed.
  • the Surface waviness of the untreated workpiece surfaces lies below ⁇ 1 mm.
  • FIG. 3 shows a cross section 31 through the workpiece 21.
  • Workpieces also consisting of levels, inclined layers, Solid bodies, hollow bodies and / or closed cavities can be manufactured, which almost means of free-form welding bodies of any shape can be produced.
  • the minimal Realizable wall thickness of the workpiece cross section 31 is 4 mm for the used Arc welding device, and 0.8 mm at the Use of a laser beam welding device. Any larger wall thicknesses can be achieved by applying additional Welding material layers can be achieved.
  • FIG. 4 illustrates the control concept of the system controller 10, which allows irregularities in sheet-like layers to be compensated for with the next covering layer of welding material.
  • a section of two superimposed, web-shaped welding material layers of the workpiece 21 (FIG. 2) is shown, with the web length l of the superimposed layers being plotted as the abscissa and the total height h of the layers as the ordinate.
  • FIG. 2 It can be seen from FIG. 2 that the shape of the workpiece 21 requires a wedge-shaped course of the layer thickness increasing to the right.
  • the web-shaped layers are preferably applied in such a way that the new layer runs approximately horizontally. In order to apply the layer 42 horizontally, the existing layer 41 was therefore brought into a correspondingly wedge-shaped position.
  • the course of the welding material layers as well as the approximate welding material application rate and / or welding track speed are predefined by the computer system 11 in the sense of a control.
  • the course of the layer height of the underlying layer 41, expressed more differentially, the distance between the contact nozzle 501 (FIG. 5) of the welding torch and the closest metallic workpiece surface can be determined continuously by the system controller 10 by measuring welding parameters, preferably welding current and welding voltage, during the welding process .
  • the system controller 10 preferably regulates the welding material application rate and / or the welding web speed in such a way that the distance between the contact nozzle 501 and the newly applied welding material web is kept constant, so that irregularities are compensated for.
  • Welding material webs are preferably applied in a position around the horizontal, because the liquid welding material in this position has the most compensating effect with regard to irregularities.
  • the system controller 10 endeavors to maintain a constant distance between the contact nozzle 501 and the newly applied welding material web, for example during the next horizontal build-up welding process, represented by the layer height profile 42, and thus irregularities such as holes or a wedge shape of the existing layer 41 by varying the Compensate welding material application rate and / or the welding path speed so that the resulting layer height profile of the new layer 42 corresponds as far as possible to the predetermined, preferably horizontal profile.
  • This control concept ensures that the welding material web applied corresponds to the specified course or, in the event of deviations, the material overlay is automatically adjusted with the next overlapping welding material web in such a way that the superimposed welding material web corresponds as closely as possible to the specified course without feedback to the higher-level computer system ( 11) must be done.
  • Recesses or holes with a depth of up to 3 mm can be compensated for by an increased amount of welding material.
  • FIG. 5 shows a vertical section through a base body 52 and a workpiece 51 with overhanging, web-shaped layers of welding material. Also shown is the welding torch 57 with the outer sheath 500, the contact nozzle 501 supplying the welding wire 56 with electricity, the arc 502 with liquid welding material and indicated flow profiles of the protective gas 503.
  • An approximate welding material application rate is predefined in front of the computer system 11. The welding voltage lying between the contact nozzle 501 and the workpiece 51 and the welding current flowing over the welding wire 56 and the arc 502 enable a continuous determination of the distance of the contact nozzle 501 from the workpiece surface 51 during the welding process, which determines the effective welding material application rate and / or welding path speed serves.
  • welding material application rate of the welding torch 57 is metered in such a way that the liquid material does not flow away, which can be determined by appropriate experiments, then welding material layers with an angle ⁇ of to overhanging on a maximally horizontal, two-dimensionally movable base body 52 with respect to the vertical tangent of the workpiece 51 at 33 ° to the vertical without a support body. Any overhanging angles ⁇ can be achieved by appropriate three-dimensional positioning of the workpiece 51.
  • FIG. 6 shows an example of a possible filling strategy for the production of a workpiece.
  • the triangular Solid body is built up from layers 61.
  • a thin workpiece contour e.g. comprehensive welding material web 62 applied and the remaining inner surface with larger ones Welding material webs 63 filled.
  • Clarification drawn disproportionately large, in each Layer of depressions 64 without application of welding material arise.
  • the next one, preferably at endpoint 67 beginning, welding material web is therefore a previous layer different filling strategy exhibit.
  • the ability of the system controller 10 To compensate for irregularities in the course of the layer height, causes pits 64 to follow the next Layer to be filled with welding material and thus a Full body can be produced without holes.
  • Fig. 7 shows a with the inventive method manufactured Pelton wheel.
  • the base body can be in one following work step a highly metalized Intermediate layer 74 by free-form welding or another suitable build-up welding method such as of the Baumkuchen method can be applied.
  • surface 73 are the individual blades 71 according to the process Free-form welding applied.
  • the workpiece 81 is through Free-form welding in layers, the respective last layer 83 to be applied preferably horizontally lies in which the workpiece 81 is inclined accordingly becomes. Layers of welding material are applied until the shape of the Pelton blade 82 is reached.
  • the shaping job welding can be done by others Machining operations on the workpiece are interrupted, e.g.
  • FIG. 9 shows, with a cross section through a Pelton blade, an example of a possible course of a welding material web on a welding material layer.
  • tracks 92 delimiting the workpiece contour tracks 91, 93 of any shape can be applied.
  • the filling strategy defined by the computer system 11 for the software-based two- or three-dimensional data model of the workpiece allows a large number of possible filling strategies, so that the strategy of layer formation shown in FIG. 8 and the course of a welding material web shown in FIG. 9 are only examples of possible implementation are considered. Not only flat, but also three-dimensional layer and path courses can be realized.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Arc Welding In General (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)
  • Metal Extraction Processes (AREA)
  • Manufacture Of Switches (AREA)
  • Piezo-Electric Or Mechanical Vibrators, Or Delay Or Filter Circuits (AREA)
  • Numerical Control (AREA)
  • Hydraulic Turbines (AREA)
  • Laser Beam Processing (AREA)
  • Lining And Supports For Tunnels (AREA)
EP91810999A 1991-01-21 1991-12-24 Verfahren zur Herstellung von metallischen Werkstücken mit einer Schweissvorrichtung und Vorrichtung zur Ausführung desselben Expired - Lifetime EP0496181B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CH164/91 1991-01-21
CH16491 1991-01-21

Publications (2)

Publication Number Publication Date
EP0496181A1 EP0496181A1 (de) 1992-07-29
EP0496181B1 true EP0496181B1 (de) 1998-08-19

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EP91810999A Expired - Lifetime EP0496181B1 (de) 1991-01-21 1991-12-24 Verfahren zur Herstellung von metallischen Werkstücken mit einer Schweissvorrichtung und Vorrichtung zur Ausführung desselben

Country Status (6)

Country Link
US (2) US5233150A (no)
EP (1) EP0496181B1 (no)
JP (1) JPH04336304A (no)
AT (1) ATE169850T1 (no)
ES (1) ES2120414T3 (no)
NO (1) NO311876B1 (no)

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US8450637B2 (en) 2008-10-23 2013-05-28 Baker Hughes Incorporated Apparatus for automated application of hardfacing material to drill bits
US8948917B2 (en) 2008-10-29 2015-02-03 Baker Hughes Incorporated Systems and methods for robotic welding of drill bits
US9439277B2 (en) 2008-10-23 2016-09-06 Baker Hughes Incorporated Robotically applied hardfacing with pre-heat
DE102016205562A1 (de) 2016-04-05 2017-10-05 Voith Patent Gmbh Verfahren zur Herstellung eines Laufrades
DE102018114635A1 (de) * 2018-06-19 2019-12-19 August Wenzler Maschinenbau GmbH Einrichtung und Verfahren zur Herstellung von Metallteilen
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USRE35756E (en) 1998-03-31
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US5233150A (en) 1993-08-03
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NO920259D0 (no) 1992-01-20
EP0496181A1 (de) 1992-07-29
NO311876B1 (no) 2002-02-11
ATE169850T1 (de) 1998-09-15

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